FLAT SHEET MEMBRANE BIOREACTOR

OPERATIONAL EXPERIENCES – A NEW ZEALAND

PERSPECTIVE

Paper Presented by:

Jason Ewert

Author:

Jason Ewert, Technical Director, Mechanical Design,

Mott MacDonald

77th Annual WIOA Victorian Water Industry Operations

Conference and Exhibition
Bendigo Exhibition Centre
2 to 4 September, 2014

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Bendigo Exhibition Centre, 2 to 4 September, 2014
 FLAT SHEET MEMBRANE BIOREACTOR OPERATIONAL
EXPERIENCES – A NEW ZEALAND PERSPECTIVE
Jason Ewert, Technical Director, Mechanical Design, Mott MacDonald

ABSTRACT

Membrane bio-reactor (MBR) technology is a relatively recent and maturing wastewater

treatment technology in Australia and New Zealand. As such literature on actual operational
experiences with full scale MBR plants in Australasia and how these experiences may be
translated into design and operational improvements is somewhat limited.

This paper discusses the operational experiences and the lessons learnt regarding operating full-
scale flat sheet MBR municipal wastewater treatment plants. In particular the discoveries made
when the first three of these types of treatment plants installed in New Zealand (at Tirau, Turangi
and Te Aroha) have been drained down for routine membrane cleaning, membrane inspection, and
damaged membrane replacement over the first 8 years of operation.

All three of the subject MBR plants experienced varying degrees of sludge caking between the
individual membrane panels and lint build-up around the membrane module housings and
associated appurtenances. The contributing factors and mechanisms for membrane caking,
associated membrane performance parameters and operational issues are discussed. Membrane
failure rates after 8 years of operation at the Tirau and Te Aroha MBR plant are also discussed.

KEYWORDS

Membrane Bioreactor, MBR, Membrane Fouling, Membrane Caking, Membrane Inspection,

Membrane Cleaning, Membrane Maintenance, Membrane Failure Rate

1.0 INTRODUCTION

The membrane bio-reactor technology is gaining popularity globally as a result of

increased effluent quality requirements and continued drivers to minimise treatment plant
footprints. The technology is proving to be successful in meeting these objectives,
however, there is a lack of practical operational information available to assist plant
operators and designers to optimise the technology.

A number of variations of membrane are available, the most common of which for
municipal wastewater are: flat sheet, hollow fibre, tubular, capillary tube, pleated filter
cartridge and spiral wound. This paper focuses on experiences with the flat sheet style of
membrane.

The flat sheet MBR plants at Turangi, Te Aroha and Tirau were the first community scale
municipal MBR installations in New Zealand and have been in operation since 2006.
During membrane inspections at all three sites some degree of sludge caking was noted
between the membrane sheets, as was a build-up of lint around the membranes, permeate
tubes, coarse bubble diffusers, membrane module housings and associated appurtenances.

This paper discusses the cause and effect of the various observations during the membrane
inspections. Improvements are suggested to reduce the occurrence of sludge caking and
lint build-up.

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1.1 Description of Kubota Flat Sheet Membrane Modules

The Kubota submerged membrane unit comprises the membrane and diffuser cases. Two
of the three plants considered in this paper employ the Kubota EK400 membrane module
which consists of two membrane cases, one stacked upon the other, with a single diffuser
case at the bottom. The EK400 module holds 400 membrane sheets (200 in each
membrane case). One of the three plants considered in this paper (Tirau WWTP) employs
the Kubota ES200 membrane module which consists of one membrane case stacked upon
a diffuser case below. The ES200 module holds 200 membrane sheets in a single case.

The sheets sit at 7 mm spacing from one another. The membrane sheets have a nominal
pore size of 0.4 micron. Sheets of chlorinated polyethylene are ultrasonically welded to
both the front and back of an ABS panel. The filtered water (permeate) is collected
through a series of recessed channels formed in the panel surface that lead to a nozzle
located at the top of the panel. Permeate is forced by the water head through each
membrane panel up through the nozzle to a collection tube above the membranes. The
permeate is then conveyed from the tubes into a common permeate header. The header
pipe then connects into the plant’s permeate pipework system. The three MBR plants that
are the subjects of this paper operate under gravity permeate discharge.

The diffuser case supports the modules off the base of the tank whilst also housing the
coarse bubble aeration diffusers. These diffusers are critical to the performance of the
system and perform two key roles: to provide oxygen for the biological process and to
scour the membrane surface to prevent fouling.

1.2 Key Indicators for Membrane Performance

The key performance indicator for the flat sheet membranes is the relationship between
trans-membrane pressure (TMP) and membrane flux rate. TMP is effectively the pressure
loss across the membrane module, and as such this provides a measure of the degree of
membrane fouling. Over time the TMP for a given flux rate will slowly trend upwards,
even after the plants specific air scour (commonly known as membrane relaxation) phase.
Eventually a chemical clean in place (CIP) is required to reverse the fouling and restore
the performance of the membrane.

1.3 Specific Treatment Plant Information

The configuration and key information relating to the three MBR plants discussed in this
paper are presented in the following table.

Table 1: WWTP summary data

Parameter Units Turangi Tirau Te Aroha
Year Commissioned AD 2006 2006 2006
Average Dry Weather Flow
m3/d 1250 300 1775
(ADWF)
Peak Wet Weather Flow
m3/d 1600 900 9805*
(PWWF)
Maximum Flow to Treatment
m3/d 2074 440 2407
(MFT)
3mm perforated 3mm perforated 2mm perforated
Inlet Screen
plate spiral sieve plate spiral sieve plate spiral sieve
Membrane Module Model Kubota EK400 Kubota ES200 Kubota EK400
Number of Modules 12 4 12

* Flows in excess of MFT capacity are treated through pre-existing oxidation ponds
th
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1.4 Membrane Sheet Sludge Caking

At each of the three plants varying degrees of sludge caking was observed between the
membrane sheets at the time of the first membrane inspection. The severity of the sludge
caking differed from plant to plant and from module to module. The sludge caking at the
Turangi WWTP during the first inspection there was the most prolific and severe.

The sludge caking at its worst was extremely thick and well compacted, forming an almost
dry dense and brittle cake, which completely filled the void between the sheets. In slightly
less severe cases the space between the sheets was filled but the level of compaction was
less, leaving the caking with more typical sludge characteristics.

Figure 1: Sludge caking between membrane sheets (Te Aroha 24/05/2010)

causing displacement of neighbouring sheets

2.0 CONTRIBUTING FACTORS TO SLUDGE CAKING

The key contributing factors for the presence of sludge caking between the membrane
sheets are discussed below.

2.1 Inlet Screening and Lint Build Up

Satisfactory influent screening is vital for the protection of the downstream membranes.
The membranes are relatively fragile and can easily be damaged by sharp objects in the
waste stream. To protect the membranes most suppliers specify a screening aperture size
of between 1 and 3 mm in all directions.

During the initial inspection of the Turangi WWTP a very high membrane sheet failure
rate was observed, in the order of 30% over a three year period. It was discovered that the
screen installed was not in accordance with the original design specification. The design
called for a 3 mm perforated plate screen, however, a 5 mm perforated plate was installed.
It is suspected that this was the main cause of the high failure rate, however pieces of a
plastic warning sign that had fallen into the tanks and been smashed up by a mixer were
also discovered during the inspection.

The plant at Te Aroha which had the correct screen had a sheet failure rate of less than 2%
on its first inspection within a similar timeframe from the commissioning of the plant. The
reported annual failure rate of membranes at the Tirau plant is 5% with no noticeable
increase in failure rate over time. In the 4 year period between 2010 and 2014 inspections,
the Te Aroha plant recorded a membrane failure rate of around 30% (7.5% per annum).
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 From observation it appears the inlet screening is required to do more than simply protect
the membrane sheets from physical damage. The inlet screening stage must also have a
high efficiency in removing lint and hair to minimise the amount of this material entering
the reactors as the presence of this fibrous material was observed to interfere with the
uniformity of the coarse bubble aeration. This is caused by a build-up (agglomeration) of
lint and hair at the base of the membrane banks and around the permeate tubes of the
lower bank restricting the free passage of airflow between the sheets above the lint
agglomerations. Figure 2 illustrates an example of severe lint/hair agglomeration at the
base of a membrane module. Significant sludge caking was observed between the
membrane sheets above.

Figure 2: Example of lint/hair agglomeration under membrane module (Turangi

WWTP)

It is recommended that MBR plants are fitted with inlet screens with an aperture size of 1-
2mm in all directions with a type of screen that has a 90° change of direction in the water
flow as the water passes through the aperture to prevent hair and fibres from
“streamlining” through the screen holes. Also screens that have a cleaning mechanism that
tends to push material through the screen apertures in the direction of flow should be
avoided in MBR installations.

2.2 Coarse Bubble Aeration Settings

Correct performance of the coarse bubble aeration system is the single most important
parameter for protecting against developing sludge caking. It is critically important that
the blower system design and operation is set up correctly to provide the necessary scour
air flow rates as prescribed by the membrane manufacturer.

Early in 2009, after nearly three years of operation at the Turangi WWTP it was
discovered that the coarse bubble aeration system was not delivering sufficient air flow in
comparison to the membrane suppliers specified air flow rate. The shortcoming in aeration
delivery appeared to have arisen from an error in the configuration of the blower variable
speed drive set points during commissioning. Upon increasing the aeration to the specified
flow rate the plant performance was noted to increase significantly.

If permeation occurs without coarse bubble aeration the membranes will foul very rapidly.
It is very important that all flat sheet MBR plants include suitable interlocks to prevent this
scenario from occurring i.e. permeate valves cannot be in an open state without the coarse
bubble aeration system in operation.

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2.3 Coarse Bubble Diffuser Blockage

Deterioration of the coarse bubble aeration pattern was witnessed at all three plants over
time. Upon draining and cleaning of the reactor tanks at the Te Aroha WWTP, the
membrane tanks were partially refilled with clean water and the coarse bubble aeration
system operated. The purpose of this was to check the uniformity of the coarse bubble
aeration pattern prior to reinstalling the cleaned and refurbished membrane modules. As
can be seen in Figure 3 below (left) considerable variation in aeration intensity was evident
across each module and from module to module.

Figure 3: Coarse Bubble Aeration Pattern Pre Diffuser Cleaning (left) and Post
Diffuser Cleaning (right) [Te Aroha WWTP]
The locations of poor coarse bubble air flow noted during the initial uniformity check
correlated very well with the areas of heavy sludge caking observed during the sheet
inspection. The membrane tanks were drained and the diffusers were cleaned. Figure 3
(right) shows the aeration pattern after the diffuser cleaning operation.

Inspection of the coarse bubble aeration diffusers at both the Turangi WWTP and the Te
Aroha WWTP showed significant blockages in both the lateral diffuser pipes and the
diffuser nozzles. A significant amount of sludge was extracted from the majority of the
diffusers, however, the areas of poorest air flow were not obviously more significantly
blocked than the other areas. Figure 4 illustrates the diffuser cleaning process.

Figure 4: Coarse bubble aeration diffuser cleaning [Te Aroha WWTP]

The postulated contributing causes of the coarse bubble aeration diffuser blockage are a
combination of:
� Ineffective inlet screening – poor fibrous solids capture efficiency allowing large
amounts of hair and lint into the treatment plant and;

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 � The current method of diffuser flushing – in the diffuser flush sequences a venturi
effect is induced in the diffuser pipework drawing MLSS into the diffuser
pipework. The shear force induced by the fluid flow is intended to clear the
diffuser nozzles of fouling and sludge build up. However, it is hypothesised that
fibrous material present in the MLSS (lint and hair) drawn into the diffusers during
the flushing sequence leads to blockages in the diffusers, which once blocked is
followed by the accumulation of sludge. This hypothesis is supported by the
observation of hair and lint within the sludge removed from the diffusers during the
diffuser cleaning procedure.

3.0 CONCLUSIONS & RECOMMENDATIONS

Based on the observations made over the first eight years of flat sheet MBR plant
operation in New Zealand and the findings from plant inspections undertaken at Turangi
WWTP, Te Aroha WWTP and Tirau WWTP a number of potential improvements are
suggested below that could improve plant performance and operability. It was noted at all
three sites that the inlet screen (despite meeting the membrane supplier’s specifications)
was failing to provide the process with suitable protection from lint and hair. The other
key area which was noted to underperform was the coarse bubble aeration system which
was observed to be unable to provide uniform scouring air in the process conditions and as
a result sludge caking was observed at all three plants. The sludge caking ultimately
reduced the achievable permeate flux from the membranes.

Some of these suggested improvements have the potential to be retrospectively

incorporated into operational plants, but all should be considered at the design stage of
any future flat sheet MBR plants.

Suggested Improvements

1. Improved Influent Screening (1-2mm with 90° direction change)

2. Continuous MLSS Screening (e.g. RAS screening)
3. Alternative Diffuser Flushing Methods (e.g. high volume flushing with permeate)
4. Fail Safe Systems to prevent permeation without aeration
5. Continuous Monitoring of Coarse Bubble Aeration Flow Rates
6. Design of Facilities for Easy Tank Draining and Membrane Cleaning

4.0 ACKNOWLEDGEMENTS

The author would like to thank the wastewater operations teams from the Matamata-
Piako District Council (Kaimai Valley Services), the Taupo District Council and the South
Waikato District Council (Watermark) for their valuable input and assistance into this
paper.

5.0 REFERENCES

Chapman S., Leslie G. and Law I. “Membrane Bioreactors (MBR) for Municipal Wastewater
Treatment – An Australian Perspective”

Judd, S. (2006) “The MBR Book – Principles and Applications of Membrane Bioreactors in
Water and Wastewater Treatment” Elsevier.

“Instruction Manual for Submerged Membrane Unit (EK type)”, English version prepared on 6
December 2004, Kubota Corporation, Tokyo, Japan

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